JCB JS Auto Range – Tracked Excavators – Tier 4 Isuzu Engine Operator Manual 9821-1800

Description

• Model List:
  • JS Auto Range – Tracked Excavators – Tier 4 Isuzu Engine

• 1. Safety Notices
• 2. Important Information …………………………………………………………………………1
• 3. The Operator Manual …………………………………………………………………….1
• 4. Safety Warnings ……………………………………………………………………………1
• 5. Introduction
• 6. About this Manual ………………………………………………………………………………3
• 7. Machine Model and Serial Number ………………………………………………….3
• 8. Using this Manual ………………………………………………………………………….3
• 9. Left Side, Right Side ………………………………………………………………………4
• 10. Cross References ………………………………………………………………………….4
• 11. Machine Description …………………………………………………………………………..5
• 12. The JCB Tracked Excavator ……………………………………………………………5
• 13. Intended Use ………………………………………………………………………………..5
• 14. Component Location ……………………………………………………………………..6
• 15. Safety Check List ……………………………………………………………………………….8
• 16. Safety – Yours and Others ………………………………………………………………8
• 17. General Safety ……………………………………………………………………………..8
• 18. Operating Safety …………………………………………………………………………10
• 19. Maintenance Safety ……………………………………………………………………..13
• 20. Safety Labels …………………………………………………………………………………..18
• 21. Introduction …………………………………………………………………………………18
• 22. Safety Label Identification …………………………………………………………….19
• 23. Identifying Your Machine …………………………………………………………………..23
• 24. Machine Identification Plate ………………………………………………………….23
• 25. Component Identification Plates …………………………………………………….24
• 26. Machine Security ……………………………………………………………………………..27
• 27. Introduction …………………………………………………………………………………27
• 28. JCB Plantguard …………………………………………………………………………..27
• 29. Construction Equipment Security And Registration Scheme (CESAR) .27
• 30. LiveLink ……………………………………………………………………………………..27
• 31. Immobiliser …………………………………………………………………………………27
• 32. Operation
• 33. Introduction ……………………………………………………………………………………..29
• 34. Before Entering the Cab ……………………………………………………………………30
• 35. Entering and Leaving the Cab ……………………………………………………………31
• 36. Standard Cab Machines ……………………………………………………………….31
• 37. Emergency Exit …………………………………………………………………………..32
• 38. Doors and Windows …………………………………………………………………………33
• 39. Opening and Closing the Door ………………………………………………………33
• 40. Opening and Closing the Front Upper Window ………………………………..33
• 41. Opening and Closing The Front Lower Window ……………………………….34
• 42. Door Sliding Window ……………………………………………………………………35
• 43. Opening and Closing the Sunblind …………………………………………………35
• 44. Access to the Upper Structure ……………………………………………………………37
• 45. Standard Machines ………………………………………………………………………37
• 46. Seat Controls …………………………………………………………………………………..38
• 47. Introduction …………………………………………………………………………………38
• 48. Operators Seat-Console ……………………………………………………………….38
• 49. Operators Seat – Standard-Heated …………………………………………………38
• 50. Air Suspension Seat …………………………………………………………………….39
• 51. Seat Belts (if fitted) …………………………………………………………………………..40
• 52. Static Seat Belt ……………………………………………………………………………40
• 53. Visibility Aids ……………………………………………………………………………………41
• 54. Mirrors ……………………………………………………………………………………….41
• 55. Cab Layout ……………………………………………………………………………………..45
• 56. Components Key …………………………………………………………………………45
• 57. Drive Controls, Switches and Instruments ……………………………………………47
• 58. Drive Controls ……………………………………………………………………………..47
• 59. Switches …………………………………………………………………………………….48
• 60. Instruments …………………………………………………………………………………55
• 61. Air Conditioning and Heater Controls ……………………………………………..60
• 62. Diesel Particulate Diffuser (DPD) …………………………………………………..62
• 63. Operating Levers-Pedals …………………………………………………………………..66
• 64. Excavating Controls …………………………………………………………………….66
• 65. Travel Speed Change Button ………………………………………………………..72
• 66. Operation Levers …………………………………………………………………………73
• 67. Optional Circuit Pedal (if fitted) ………………………………………………………74
• 68. ISO Operating Method …………………………………………………………………74
• 69. Safety Equipment …………………………………………………………………………….75
• 70. Control Locks ……………………………………………………………………………..75
• 71. Dipper Stroke Limiter (If fitted) ……………………………………………………….76
• 72. Overload Warning System …………………………………………………………….78
• 73. Before Starting the Engine …………………………………………………………………80
• 74. Starting the Engine …………………………………………………………………………..81
• 75. Warming-Up ……………………………………………………………………………….82
• 76. JCB Immobiliser System ………………………………………………………………82
• 77. Getting the Machine Moving ………………………………………………………………85
• 78. Stopping and Parking the Machine ……………………………………………………..86
• 79. Stopping and Parking …………………………………………………………………..86
• 80. Engine Shutdown ………………………………………………………………………..87
• 81. Working with your Machine ……………………………………………………………….88
• 82. Operating Practices and Site Safety ………………………………………………88
• 83. Clothing and Safety Equipment ……………………………………………………..88
• 84. Danger Zone ………………………………………………………………………………88
• 85. Log Moving-Handling ……………………………………………………………………88
• 86. Safety Practices ………………………………………………………………………….88
• 87. Working With the Excavator ………………………………………………………….90
• 88. Lifting (Object Handling) ……………………………………………………………….97
• 89. Use of Machines on Gradients and Slopes ……………………………………100
• 90. Pulling out of Soft Ground …………………………………………………………..103
• 91. Water ……………………………………………………………………………………….104
• 92. Towing Other Equipment …………………………………………………………….104
• 93. Machine Stability ……………………………………………………………………….105
• 94. Reducing Wear ………………………………………………………………………….106
• 95. Operating Environment ……………………………………………………………………109
• 96. Maintenance in Cold Climates ……………………………………………………..109
• 97. Operating in a Cold Climate (Below 0°C) ………………………………………109
• 98. Operating in a Hot Climate (Above 35°C) ……………………………………..109
• 99. Operating in Dusty or Sandy Areas ……………………………………………… 110
• 100. Operating in Coastal Regions …………………………………………………….. 110
• 101. Operating on Wet or Soft Ground ………………………………………………… 110
• 102. Cab Filters ……………………………………………………………………………….. 110
• 103. Refuelling the Machine …………………………………………………………………… 111
• 104. Low Fuel Levels ……………………………………………………………………….. 111
• 105. Filling the Tank …………………………………………………………………………. 111
• 106. Fuel Level ………………………………………………………………………………… 112
• 107. Refuelling Pump ……………………………………………………………………….. 113
• 108. Moving a Disabled Machine ……………………………………………………………. 114
• 109. Lowering the Boom in an Emergency ………………………………………….. 114
• 110. Retrieval ………………………………………………………………………………….. 114
• 111. Limp Mode ……………………………………………………………………………….. 115
• 112. Transporting the Machine ……………………………………………………………….. 116
• 113. Lifting the Machine ………………………………………………………………………… 118
• 114. JS240- JS360 Machines ……………………………………………………………. 118
• 115. Storage of the Machine …………………………………………………………………..120
• 116. Introduction ……………………………………………………………………………….120
• 117. Storage Area …………………………………………………………………………….120
• 118. Prepare the Machine for Storage …………………………………………………120
• 119. Put the Machine into Storage ………………………………………………………120
• 120. During Storage ………………………………………………………………………….120
• 121. Take the Machine Out of Storage …………………………………………………121
• 122. Anti-Vandalism Guards (option) ………………………………………………………..122
• 123. Unpacking the Guards ………………………………………………………………..122
• 124. Fitting the Guards ………………………………………………………………………122
• 125. Removing the Guards ………………………………………………………………..123
• 126. Storing the Guards …………………………………………………………………….123
• 127. Routine Maintenance
• 128. Service Requirements …………………………………………………………………….125
• 129. Introduction ……………………………………………………………………………….125
• 130. Owner-Operator Support …………………………………………………………….125
• 131. Service-Maintenance Agreements ……………………………………………….125
• 132. Fit for Purpose Tests for Lifting Equipment …………………………………….126
• 133. Obtaining Replacement Parts ………………………………………………………126
• 134. Health and Safety …………………………………………………………………………..127
• 135. Lubricants …………………………………………………………………………………127
• 136. Battery ……………………………………………………………………………………..129
• 137. Service Schedules ………………………………………………………………………….131
• 138. Introduction ……………………………………………………………………………….131
• 139. How to Use the Service Schedules ………………………………………………131
• 140. Calendar Equivalents …………………………………………………………………131
• 141. Pre Start Cold Checks, Service Points and Fluid Levels ………………….132
• 142. Functional Test and Final Inspection …………………………………………….136
• 143. Service Intervals for Attachments …………………………………………………138
• 144. Periodic Replacement of Safety Related Components ……………………139
• 145. Fluids, Lubricants and Capacities ……………………………………………………..140
• 146. JS240-260 and Variants ……………………………………………………………..140
• 147. JS330-360 and Variants ……………………………………………………………..141
• 148. Typical Lubrication Chart …………………………………………………………….142
• 149. Coolant Mixtures ……………………………………………………………………….143
• 150. Fuel …………………………………………………………………………………………144
• 151. Tools …………………………………………………………………………………………….146
• 152. Carrying Tools onto the Machine ………………………………………………….146
• 153. Locations ………………………………………………………………………………….146
• 154. Prepare the Machine for Maintenance ………………………………………………147
• 155. Introduction ……………………………………………………………………………….147
• 156. How to Make the Machine Safe (Excavator Lowered) …………………….147
• 157. Cleaning the Machine ……………………………………………………………………..148
• 158. Introduction ……………………………………………………………………………….148
• 159. Preparing the Machine for Cleaning ……………………………………………..148
• 160. Cleaning the Machine …………………………………………………………………149
• 161. Cleaning the Tracks ……………………………………………………………………149
• 162. Cleaning the Radiator and Oil Cooler ……………………………………………149
• 163. Checking for Damage ……………………………………………………………………..150
• 164. Check the Machine Body and Structure ………………………………………..150
• 165. Check the Seat and Seat Belt ……………………………………………………..150
• 166. Checking the FOPS Structure ……………………………………………………..150
• 167. Daily Checking ……………………………………………………………………………….152
• 168. Greasing ……………………………………………………………………………………….154
• 169. Introduction ……………………………………………………………………………….154
• 170. Slew Ring Bearing ……………………………………………………………………..154
• 171. Slew Ring Teeth and Slew Pinion …………………………………………………154
• 172. Greasing Points …………………………………………………………………………155
• 173. Electrical System ……………………………………………………………………………157
• 174. Battery ……………………………………………………………………………………..157
• 175. Jump-Starting the Engine ……………………………………………………………162
• 176. Fuses and Relays – Cab ……………………………………………………………..163
• 177. Fuses and Relays – Battery Bay …………………………………………………..164
• 178. Bolt and Nut Torque Specifications ……………………………………………………165
• 179. JS240-360 and Variants ……………………………………………………………..165
• 180. Engine ………………………………………………………………………………………….171
• 181. Oil and Filter ……………………………………………………………………………..171
• 182. Cooling System …………………………………………………………………………173
• 183. Fan Belt ……………………………………………………………………………………177
• 184. Engine Air Filter …………………………………………………………………………178
• 185. Fuel System …………………………………………………………………………………..180
• 186. Introduction ……………………………………………………………………………….180
• 187. Draining Fuel Tank Impurities ………………………………………………………180
• 188. Draining the Primary Filter-Sedimenters ……………………………………….181
• 189. Changing the Primary Filter-Sedimenter Element …………………………..182
• 190. Changing the Fuel Feed Pump Filter ……………………………………………182
• 191. Draining the Main Filter-Sedimenter ……………………………………………..183
• 192. Changing the Main Filter-Sedimenter Element ……………………………….184
• 193. Bleeding the System ………………………………………………………………….185
• 194. Hydraulic System ……………………………………………………………………………186
• 195. Introduction ……………………………………………………………………………….186
• 196. Releasing Tank Pressure ……………………………………………………………187
• 197. Releasing the Hydraulic Pressure ………………………………………………..187
• 198. Oil and Filters ……………………………………………………………………………188
• 199. Draining Water and Sediment from the Hydraulic Tank ……………………195
• 200. Air Bleeding Procedures ……………………………………………………………..195
• 201. Slew Gearbox ………………………………………………………………………………..197
• 202. Checking the Slew Gearbox Oil Level …………………………………………..197
• 203. Changing the Slew Gearbox Oil …………………………………………………..197
• 204. Tracks and Running Gear ……………………………………………………………….198
• 205. Tracks ………………………………………………………………………………………198
• 206. Running Gear ……………………………………………………………………………200
• 207. Bucket ………………………………………………………………………………………….201
• 208. Checking-Adjusting For Side Play ………………………………………………..201
• 209. Windscreen Washer ……………………………………………………………………….202
• 210. Checking the Level …………………………………………………………………….202
• 211. Fire Extinguisher (If fitted) ……………………………………………………………….203
• 212. Troubleshooting ……………………………………………………………………………..204
• 213. Engine and Related Area ……………………………………………………………204
• 214. Monitor Display – Fault Messages ………………………………………………..207
• 215. Operations ………………………………………………………………………………..208
• 216. Hydraulic pump …………………………………………………………………………209
• 217. Working Attachments …………………………………………………………………210
• 218. Travel ………………………………………………………………………………………. 211
• 219. Slew …………………………………………………………………………………………212
• 220. Hydraulic ram ……………………………………………………………………………212
• 221. Optional Attachments
• 222. Introduction ……………………………………………………………………………………213
• 223. Attachments For Your Machine ………………………………………………………..214
• 224. Connecting-Disconnecting Hydraulic Hoses ……………………………………….215
• 225. Introduction ……………………………………………………………………………….215
• 226. Connecting the Hydraulic Hoses ………………………………………………….215
• 227. Disconnecting the Hydraulic Hoses ………………………………………………216
• 228. Quick Release Couplings ……………………………………………………………217
• 229. Operating Attachments ……………………………………………………………………219
• 230. Grab-Changeover Valves (if fitted) ……………………………………………….220
• 231. Hydraulic Rockbreaker ……………………………………………………………………222
• 232. Preparation ……………………………………………………………………………….222
• 233. Operation and Maintenance ………………………………………………………..222
• 234. Crusher …………………………………………………………………………………………223
• 235. General …………………………………………………………………………………….223
• 236. Preparation ……………………………………………………………………………….223
• 237. Weedcutter ……………………………………………………………………………………224
• 238. Operation ………………………………………………………………………………….224
• 239. Maintenance ……………………………………………………………………………..224
• 240. Specifications
• 241. Static Dimensions …………………………………………………………………………..225
• 242. JS240-260 – Monoboom ……………………………………………………………..225
• 243. JS240-260 – Triple Articulated Boom …………………………………………….226
• 244. JS260 – Long Reach …………………………………………………………………..227
• 245. JS330 – Monoboom ……………………………………………………………………228
• 246. JS330 – Triple Articulated Boom …………………………………………………..229
• 247. JS360 – Monoboom ……………………………………………………………………230
• 248. Dig Depth Chart ……………………………………………………………………………..231
• 249. JS240-260 – Monoboom ……………………………………………………………..231
• 250. JS240-260 – Triple Articulated Boom …………………………………………….232
• 251. JS260 – Long Reach …………………………………………………………………..233
• 252. JS330 – Standard Monoboom ………………………………………………………235
• 253. JS330 – Triple Articulated Boom …………………………………………………..236
• 254. JS330 – ME Monoboom ………………………………………………………………237
• 255. JS360 – Standard Monoboom ………………………………………………………238
• 256. Shipping Weight …………………………………………………………………………….239
• 257. Travel Speeds ………………………………………………………………………………..240
• 258. Noise Data …………………………………………………………………………………….241
• 259. Introduction ……………………………………………………………………………….241
• 260. All Machines ……………………………………………………………………………..241
• 261. Vibration Data ………………………………………………………………………………..242
• 262. Introduction ……………………………………………………………………………….242
• 263. JS240-260 ………………………………………………………………………………..243
• 264. JS330 ………………………………………………………………………………………244
• 265. JS360 ………………………………………………………………………………………245
• 266. Lifting (Object Handling) Regulations and Safe Working Loads …………….246
• 267. Introduction ……………………………………………………………………………….246
• 268. Load Charts ………………………………………………………………………………247
• 269. Warranty Information
• 270. Machine Service Record Sheet ………………………………………………………..265
• 271. Registration Information ………………………………………………………………….267
• 272. European Community Standards
• 273. EC Declaration of Conformity …………………………………………………………..269
• 274. Introduction ……………………………………………………………………………….269
• 275. Explanation of the EC Declaration of Conformity ……………………………271